ES2986609T3 - Aerosol generating substrate element with double paper wraps - Google Patents

Abstract

An aerosol-generating substrate element is bounded by exactly two paper layers that do not extend beyond an aerosol-generating substrate. The aerosol-generating substrate includes about 10% to about 30% glycerin by weight. The first paper wrapper and the second paper wrapper have a combined thickness in a range of about 60 micrometers to about 200 micrometers. The first paper wrapper does not overlap itself, and a second paper wrapper does not overlap itself. (Automatic translation with Google Translate, no legal value)

Description

DESCRIPTION

Aerosol generating substrate element with double paper wraps

The present disclosure relates to dual paper wrappers used in an aerosol-generating substrate element. An aerosol-generating substrate is circumscribed exactly by two layers of paper wrapper to form an aerosol-generating substrate element.

Aerosol-generating articles are known in the art in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than burned. Typically, in these heated aerosol-generating articles, the aerosol is generated by heat transfer from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in the air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

The paper used to wrap the aerosol-generating substrate and form the aerosol-generating element may absorb aerosol-former, water, and other liquid compounds found in mainstream smoke or aerosol passing through the aerosol-generating article, or moisture surrounding the paper. The absorbed liquid may stain or weaken the paper and adversely affect the appearance and structural integrity of the aerosol-generating article. Heated aerosol-generating articles are particularly susceptible to wetting and tearing due to the high levels of aerosol-former in the aerosol-generating substrate of these heated aerosol-generating articles. Heated aerosol-generating articles are particularly susceptible to swelling as aerosol components are absorbed by the wrap, leading to difficult removal from the heating device.

A resistive heating sheet may be inserted into the aerosol-generating substrate to heat the aerosol-generating substrate and release volatile compounds from the aerosol-generating substrate. The resistive heating sheet may provide a localized heat source within the aerosol-generating substrate that may be located along a central axis of the aerosol-generating substrate. The aerosol-generating substrate located around the periphery or interface with the paper wrapper may not be sufficiently heated by the centrally located resistive heating sheet, resulting in unused aerosol-generating substrate within the aerosol-generating element.

WO 2010/043475 A1 describes a smoking article comprising a rod of smoking material and a first sheet-like material comprising at least one diluent. US 5131416 A describes a cigarette including a charge or roll of smoking material circumscribed by two layers of paper wrapping materials.

It would be desirable to provide a visually and mechanically stable aerosol-generating substrate element, particularly for heated, but not burned aerosol-generating substrates that contain a high level of liquids or aerosol formers. It would also be desirable if this thick paper layer did not affect the taste of the aerosol generated by the aerosol-generating substrate element.

It would be desirable to provide an aerosol generating substrate element that reduces the amount of unused aerosol generating substrate within the aerosol generating element.

It would be desirable if this wrapper does not burn easily if it is near a heating element and does not adversely affect the heating of the aerosol generating substrate which is heated, but not burned.

An object of the invention may be to at least partially solve one or more of the above-mentioned desirable technical benefits.

In accordance with this disclosure, there is provided an aerosol-generating substrate element comprising a cylindrical aerosol-generating substrate and a first paper wrapper and a second paper wrapper circumscribing the aerosol-forming substrate. The first paper wrapper and the second paper wrapper have a combined thickness in a range of about 60 microns to about 200 microns. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol-generating substrate. The first paper wrapper does not overlap itself and a second paper wrapper does not overlap itself.

Preferably, an aerosol-generating substrate element comprising a cylindrical aerosol-generating substrate and a first paper wrapper and a second paper wrapper circumscribing the aerosol-forming substrate. The cylindrical aerosol-generating substrate includes from about 10% to about 30% glycerin by weight. The first paper wrapper and the second paper wrapper have a combined thickness in a range of about 60 microns to about 200 microns. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol-generating substrate. The first paper wrapper does not overlap itself and a second paper wrapper does not overlap itself.

In accordance with this disclosure, there is provided an aerosol-generating substrate element comprising a cylindrical aerosol-generating substrate, a first paper wrapper, and a second paper wrapper circumscribing the first paper wrapper. The first paper wrapper comprises opposing edges abutting each other to circumscribe the aerosol-forming substrate and form a first seam line. The second paper wrapper comprises opposing edges abutting each other to circumscribe the first paper wrapper and form a second seam line. The first seam line is offset from the second seam line. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol-generating substrate.

Preferably the first seam line is offset from the second seam line by at least about 5%, or at least about 10%, or at least about 15% of a circumference of the aerosol-generating substrate.

Preferably, the aerosol-generating substrate is circumscribed by less than three layers of paper at any point around a circumference of the aerosol-generating substrate that does not extend beyond the aerosol-generating substrate.

The first paper wrapper and the second paper wrapper may have a combined thickness in a range of about 78 micrometers to about 160 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in a range of about 78 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in a range of about 90 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in a range of about 100 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in a range of about 110 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in a range of about 125 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in a range of about 130 micrometers to about 140 micrometers.

The first paper wrapper and the second paper wrapper may have a uniform combined thickness that does not differ at any point around a circumference of the aerosol-generating substrate element by more than about 30 micrometers, or more than about 20 micrometers, or more than about 10 micrometers, or more than about 5 micrometers.

The aerosol-generating substrate may define a substantially cylindrical shape having a diameter in a range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm.

The first paper wrapper and the second paper wrapper may have a combined thickness to tobacco substrate diameter ratio in a range of about 1:120 to about 1:40. The first paper wrapper and the second paper wrapper may have a combined thickness to tobacco substrate diameter ratio in a range of about 1:100 to about 1:50. The first paper wrapper and the second paper wrapper may have a combined thickness to tobacco substrate diameter ratio in a range of about 1:70 to about 1:50. The first paper wrapper and the second paper wrapper may have a combined thickness to tobacco substrate diameter ratio in a range of about 1:60 to about 1:50.

The aerosol-generating substrate may include homogenized tobacco material. The homogenized tobacco material may include tobacco material, from about 1 percent to about 5 percent of a binder, and from about 5 percent to about 30 percent of an aerosol former, on a dry weight basis. The aerosol-generating substrate may include a shirred sheet of homogenized tobacco material, which is preferably crimped.

Preferably, the aerosol-generating substrate may include homogenized tobacco material. The homogenized tobacco material may include tobacco material, from about 1 percent to about 5 percent of a binder, and from about 10 percent to about 30 percent glycerin, on a dry weight basis. The aerosol-generating substrate may include a shirred sheet of homogenized tobacco material, which is preferably crimped.

The aerosol-generating substrate may include a metallic induction heating element. The aerosol-generating substrate may include a plurality of metallic induction heating elements.

In accordance with this disclosure, there is provided an aerosol generating system comprising the aerosol generating article described herein and an aerosol generating device comprising a heating element configured to heat the aerosol generating substrate.

The heating element may be a resistive heating foil element configured to be inserted into the aerosol-generating substrate. The heating element may be an inductive heating element configured to inductively heat metallic inductive heating elements incorporated within the aerosol-generating substrate.

Advantageously, aerosol-generating substrate elements that include a thick double wrap can provide a visually and mechanically stable aerosol-generating substrate element, particularly for heated, but not burned aerosol-generating substrates that contain a high level of liquids or aerosol formers. As a result, swelling, visible staining, and physical weakening of the wrap portion of the aerosol-generating article can be reduced even when a high level of humectant is included in the aerosol-generating substrate.

Advantageously, aerosol-generating substrate elements including a thick double wrapper can be formed on manufacturing equipment that forms conventional substrate elements. This can improve the processability of the aerosol-generating substrate elements and reduce manufacturing costs.

Advantageously, aerosol-generating substrate elements that include a thick double wrap can increase the amount of aerosol-generating substrate that is evenly heated and consumed, thereby reducing unused or wasted aerosol-generating substrate material.

Advantageously, the aerosol-generating substrate elements including a thick double wrapper may utilize internal heating of the aerosol-generating substrate by induction or resistive heating elements built into or inserted into the aerosol-generating substrate, and the thick double wrapper wrapping the aerosol-generating substrate may not adversely affect the heating of the aerosol-generating substrate which is heated but not burned.

A conventional cigarette is lit when a user applies a flame to one end of the cigarette and draws air through the other end. The localized heat provided by the flame and oxygen in the air drawn through the cigarette causes the end of the cigarette to ignite, and the resulting combustion generates inhalable smoke. In contrast, in heated aerosol-generating articles, an aerosol is generated by heating a flavor-generating substrate, such as tobacco. Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles and aerosol-generating articles in which an aerosol is generated by heat transfer from a combustible fuel element or heat source to a physically separate aerosol-forming substrate. For example, aerosol-generating articles according to the disclosure find particular application in aerosol-generating systems comprising an electrically heated aerosol-generating device having an internal heating sheet that is adapted to be inserted into the rod of the aerosol-generating substrate. Aerosol-generating articles of this type are described in the prior art, for example in EP 0822670.

As used herein, the term “aerosol-generating device” refers to a device comprising a heating element that interacts with the aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

As used herein, the term “aerosol-generating system” refers to a combination of an aerosol-generating device and an aerosol-generating article.

As used herein, the term “aerosol-generating article” refers to an article that includes an aerosol-generating substrate that is heated to produce and deliver inhalable aerosol to a consumer.

The term “aerosol-generating substrate element” is used herein to denote an aerosol-generating substrate wrapped with a layer of paper to form a portion of an aerosol-generating article.

The term “aerosol-generating substrate” refers to a substance capable of generating or releasing an aerosol. The aerosol-generating substrate may be a solid, paste, gel, suspension, liquid, or comprise any combination of solid, paste, gel, suspension, and liquid compositions. Preferably the aerosol-generating substrate is a solid, or a gel composition. The aerosol-generating substrate may preferably include nicotine.

As used herein, the term “mouthpiece” refers to the portion of the aerosol-generating article designed to come into contact with the mouth of the consumer. The mouthpiece may be the portion of the aerosol-generating article that may include a filter or, in some cases, the mouthpiece may be defined by the extension of the tip wrap.

The terms “upstream” and “downstream” refer to the relative positions of the elements of the aerosol-generating article described in relation to the direction of the aerosol as it is drawn from an aerosol-generating substrate and through the mouthpiece.

The aerosol-generating substrate elements of the present invention include an aerosol-generating substrate wrapped with a thick double wrap. The aerosol-generating substrate element includes an aerosol-generating substrate and exactly two layers of paper circumscribing the aerosol-generating substrate.

The aerosol-generating substrate element includes a cylindrical aerosol-generating substrate element and a first paper wrapper and a second paper wrapper circumscribing the aerosol-forming substrate. The first paper wrapper and the second paper wrapper have a combined thickness in a range of about 60 micrometers to about 200 micrometers. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol-generating substrate. The first paper wrapper does not overlap itself and a second paper wrapper does not overlap itself.

The aerosol-generating substrate element includes a cylindrical aerosol-generating substrate, a first paper wrapper, and a second paper wrapper. The first paper wrapper comprises opposing edges that abut one another to circumscribe the aerosol-forming substrate and form a first seam line. The second paper wrapper comprises opposing edges that abut one another to circumscribe the first paper wrapper and form a second seam line. The first seam line is offset from the second seam line and the first paper wrapper and the second paper wrapper do not extend beyond the aerosol-generating substrate.

Preferably the first seam line may be offset from the second seam line by at least about 5% of a circumference of the aerosol-generating substrate. Preferably the first seam line may be offset from the second seam line by at least about 10% of a circumference of the aerosol-generating substrate. Preferably the first seam line may be offset from the second seam line by at least about 15% of a circumference of the aerosol-generating substrate.

The seam line may define a space or void that is less than 10 micrometers in lateral dimension, or less than 5 micrometers in lateral dimension, or less than 2 micrometers in lateral dimension. Preferably the seam line does not define a space. Preferably the opposite edges of the paper layer abut each other without an overlap. Preferably the opposite edges of the paper layer contact each other without an overlap.

Preferably the first seam line may be offset from the second seam line in a range of about 5% to about 20% of a circumference of the aerosol-generating substrate. Preferably the first seam line may be offset from the second seam line in a range of about 5% to about 15% of a circumference of the aerosol-generating substrate. Preferably the first seam line may be offset from the second seam line in a range of about 10% to about 20% of a circumference of the aerosol-generating substrate.

The first seam line may be parallel to the second seam line. The first seam line may extend along the entire length of the aerosol-generating substrate. The second seam line may extend along the entire length of the aerosol-generating substrate. The first seam line may be parallel to the second seam line along the entire length of the aerosol-generating substrate.

The aerosol-generating substrate may be circumscribed by fewer than three layers of paper at any point around a circumference of the aerosol-generating substrate that does not extend beyond the aerosol-generating substrate. The aerosol-generating substrate may be circumscribed by fewer than three layers of paper at any point along a length of the aerosol-generating substrate that does not extend beyond the aerosol-generating substrate. Preferably, the aerosol-generating substrate may be circumscribed by fewer than three layers of paper at any point around a circumference, and at any point along a length of the aerosol-generating substrate that does not extend beyond the aerosol-generating substrate.

A combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 60 micrometers to about 200 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 78 micrometers to about 160 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 78 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 90 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 100 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 110 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 125 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in a range of about 130 micrometers to about 140 micrometers.

The first paper wrapper may have a thickness in a range of about 25 micrometers to about 175 micrometers. The first paper wrapper may have a thickness in a range of about 50 micrometers to about 150 micrometers. The first paper wrapper may have a thickness in a range of about 75 micrometers to about 125 micrometers. The first paper wrapper may have a thickness in a range of about 100 micrometers to about 140 micrometers.

The second paper wrapper may have a thickness in a range of about 25 micrometers to about 175 micrometers. The second paper wrapper may have a thickness in a range of about 50 micrometers to about 150 micrometers. The second paper wrapper may have a thickness in a range of about 75 micrometers to about 125 micrometers. The second paper wrapper may have a thickness in a range of about 100 micrometers to about 140 micrometers.

The first paper wrapper and the second paper wrapper may have essentially equal thicknesses. The first paper wrapper may have a greater thickness than the second paper wrapper. The second paper wrapper may have a greater thickness than the first paper wrapper.

The first paper wrapper may be secured to the second paper wrapper. The first paper wrapper may be adhered to the second paper wrapper. The first paper wrapper may be adhered to the second paper wrapper with an adhesive material. The adhesive material may have a thickness in a range of about 1 micrometer to about 30 micrometers, or about 5 micrometers to about 25 micrometers, about 10 micrometers to about 25 micrometers. The adhesive material may be uniformly applied to the first paper wrapper and the second paper wrapper. The adhesive material may separate the first paper wrapper from the second paper wrapper.

The first paper wrapper and the second paper wrapper may have a uniform combined thickness that does not differ at any point around a circumference of the aerosol-generating substrate element by more than about 30 micrometers. Preferably, the first paper wrapper and the second paper wrapper may have a uniform combined thickness that does not differ at any point around a circumference of the aerosol-generating substrate element by more than about 20 micrometers. Preferably, the first paper wrapper and the second paper wrapper may have a uniform combined thickness that does not differ at any point around a circumference of the aerosol-generating substrate element by more than about 10 micrometers. Preferably, the first paper wrapper and the second paper wrapper may have a uniform combined thickness that does not differ at any point around a circumference of the aerosol-generating substrate element by more than about 5 micrometers.

The first paper wrapper may not extend beyond the ends of the aerosol-generating substrate. The second paper wrapper may not extend beyond the ends of the aerosol-generating substrate. The first paper wrapper and the second paper wrapper may not extend beyond either end of the aerosol-generating substrate.

The aerosol-generating substrate element includes a cylindrical aerosol-generating substrate, a first paper wrapper, and a second paper wrapper. The first paper wrapper comprises opposing edges that abut each other to circumscribe the aerosol-forming substrate and form a first seam line wherein the first paper wrapper does not overlap or overlap itself. The second paper wrapper comprises opposing edges that abut each other to circumscribe the first paper wrapper and form a second seam line wherein the first paper wrapper does not overlap or overlap itself. The first seam line is offset from the second seam line and the first paper wrapper and the second paper wrapper do not extend beyond the aerosol-generating substrate. Reducing an overlap or overlap of the paper wrapper over itself can help prevent or minimize void spaces or air pockets defined between the paper layers.

The first and second paper wrappers may not extend beyond the ends of the aerosol-generating substrate. Preferably, the first and second paper wrappers circumscribe a full length of the aerosol-generating substrate between the ends of the aerosol-generating substrate. Preferably, the first and second paper wrappers circumscribe a full length of the aerosol-generating substrate between the ends of the aerosol-generating substrate and do not extend beyond one or both ends of the aerosol-generating substrate.

The first and second paper wrappers may circumscribe the aerosol-generating substrate to define the aerosol-generating substrate element having a substantially cylindrical shape. The aerosol-generating substrate may define a substantially cylindrical shape having a diameter in a range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm. The aerosol-generating substrate element may define a substantially cylindrical shape having a diameter in a range of about 7.1 mm to about 7.3 mm or about 7.15 mm to about 7.25 mm.

The first and second paper wrappers have a ratio of the combined paper thickness to the tobacco substrate diameter in a range of about 1:120 to about 1:40, or about 1:100 to about 1:50, or about 1:70 to about 1:50, or about 1:60 to about 1:50. Conventionally wrapped tobacco substrates may have a ratio of the paper thickness to the tobacco substrate diameter of about 1:300.

The first and second paper wrappers have a ratio of the combined paper thickness to the tobacco substrate element diameter in a range of about 1:100 to about 1:40, or about 1:75 to about 1:50, or about 1:65 to about 1:50, or about 1:60 to about 1:50. Conventionally wrapped tobacco substrates may have a ratio of the paper thickness to the tobacco substrate element diameter of about 1:300.

The aerosol-generating substrate element preferably includes an aerosol-generating substrate having a diameter in a range of about 6.8 mm to about 7.1 mm and a first paper wrapper and the second paper wrapper of combined paper thickness in a range of about 78 microns to 160 microns that circumscribe the aerosol-generating substrate and the first paper wrapper and the second paper wrapper do not overlap each other. Preferably the first paper wrapper and the second paper wrapper do not extend beyond the ends of the aerosol-generating substrate. Preferably the first paper wrapper and the second paper wrapper circumscribe an entire length of the aerosol-generating substrate.

An aerosol-generating article may comprise an aerosol-generating substrate and a nozzle. The nozzle may comprise a filter. A tip wrap may attach the filter to the aerosol-generating substrate. One or more intermediate sections may separate the aerosol-generating substrate and a nozzle.

The tip wrap may be adhered to the first paper wrap or the second paper wrap. Preferably the tipping paper extends from the nozzle or filter segment to the aerosol-generating substrate element. Preferably the tipping paper extends from the nozzle or filter segment to the aerosol-generating substrate element and contacts and adheres to the second outer surface of the paper wrap. The tipping paper preferably extends only over a downstream portion of the aerosol-generating substrate element. The tip wrap may cover 25% or less downstream of the aerosol-generating substrate element.

An aerosol-generating substrate may be a solid composition. This composition may include plant-derived material. The aerosol-generating substrate may include tobacco, and preferably the tobacco contains volatile tobacco flavoring compounds, which are released from the aerosol-generating substrate upon heating. The aerosol-generating substrate may comprise homogenized tobacco material, an aerosol former, and a binder.

Nicotine may be present in the aerosol-generating substrate in a range of about 0.5 to about 10% by weight of nicotine, or about 0.5 to about 5% by weight of nicotine. Preferably, the aerosol-generating substrate may include about 1 to about 3% by weight of nicotine, or about 1.5 to about 2.5% by weight of nicotine, or about 2% by weight of nicotine.

The aerosol-generating substrate may comprise any suitable type or types of tobacco or tobacco substitute material, in any suitable form. The aerosol-generating substrate may include atmosphere-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, specialty tobacco, homogenized or reconstituted tobacco, or any combination thereof. The aerosol-generating substrate may be provided in the form of cut tobacco, tobacco sheet, processed tobacco materials, such as bulk-expanded tobacco or puffed tobacco, processed tobacco stems, such as rolled cut stems or puffed cut stems, homogenized tobacco, reconstituted tobacco, molded leaf tobacco, or mixtures thereof, and the like. The term “cut tobacco” is used herein to indicate a tobacco material that is predominantly formed from the sheet portion of the tobacco leaf. The term “cut tobacco” is used herein to indicate both a single Nicotiana species and two or more Nicotiana species that form a cut tobacco mixture.

When used herein, the term “homogenized tobacco” denotes a material formed by agglomerating tobacco into particles. Homogenized tobacco may include reconstituted tobacco or reconstituted tobacco sheet tobacco, or a mixture of both. The term “reconstituted tobacco” refers to a paper-like material that may be made from tobacco by-products, such as very short tobacco fibers, tobacco dust, tobacco stems, or a mixture of the foregoing. Reconstituted tobacco may be made by extracting the soluble chemicals in the tobacco by-products, processing the remaining tobacco fibers into a sheet, and then reapplying the extracted materials in concentrated form to the sheet. The term “reconstituted tobacco sheet tobacco” is used herein to refer to a product resulting from a process well known in the art, which is based on straining a slurry comprising ground tobacco particles and a binder (e.g., guar) onto a support surface, such as a conveyor belt, drying the slurry, and removing the dried sheet from the support surface. Exemplary methods for producing these types of aerosol-generating substrates are described in US 5,724,998; US 5,584,306; US 4,341,228; US 5,584,306 and US 6,216,706. The homogenized tobacco may be formed into a sheet that is crimped, convoluted, folded, or otherwise compressed, prior to being wrapped to form a rod. For example, sheets of homogenized tobacco material for use in the invention may be curled by the use of a curling unit of the type described in CH-A-691156, comprising a pair of rotatable curling rollers. However, it will be appreciated that sheets of homogenized tobacco material for use in the invention may be textured by the use of other suitable machinery and processes which deform or perforate the sheets of homogenized tobacco material.

The aerosol-generating substrate used in aerosol-generating articles typically includes a higher level of aerosol former(s) than combustible smoking articles, such as cigarettes. Humectants may also be referred to as an “aerosol former.” An aerosol former is used to describe any known suitable compound or mixture of compounds that, in use, facilitates the formation of an aerosol and is substantially resistant to thermal degradation at the operating temperature of the aerosol-generating substrate. Suitable aerosol formers are known in the art and include, but are not limited to: polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols, such as glycerin mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Preferred aerosol formers are polyhydric alcohols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol and most preferably glycerol or glycerine. The aerosol-generating substrate may comprise a single aerosol-forming agent. Alternatively, the aerosol-generating substrate may comprise a combination of two or more aerosol-forming agents.

The aerosol-generating substrate may have a high level of aerosol former. As used herein, a high level of aerosol former means an aerosol former content of greater than about 10%, or preferably greater than about 15%, or more preferably greater than about 20%, by weight. The aerosol-generating substrate may also have an aerosol former content of between about 10% and about 30%, about 15% and about 30%, or about 20% and about 30%, by weight. The aerosol-generating substrate may also have a glycerin content of between about 10% and about 30%, about 15% and about 30%, or about 20% and about 30%, by weight.

The aerosol-generating substrate may comprise at least about 1%, or at least about 2%, or at least about 5%, or at least about 7%, or at least about 10%, or at least about 12%, or at least about 15%, or at least about 18% aerosol former, by weight. The aerosol-generating substrate may comprise aerosol former in a range of about 1 to about 20%, or about 5 to about 20%, or about 10 to about 20%, by weight.

The aerosol-generating substrate may comprise at least about 1%, or at least about 2%, or at least about 5%, or at least about 7%, or at least about 10%, or at least about 12%, or at least about 15%, or at least about 18% glycerin, by weight. The aerosol-generating substrate may comprise glycerin in a range of about 1 to about 20%, or about 5 to about 20%, or about 10 to about 20%, by weight.

Preferably, the aerosol-generating article may be generally cylindrical. This allows for a smooth flow of the aerosol. The aerosol-generating article may have an external diameter, for example, between 7.1 millimetres and 7.3 millimetres, or 7.15 millimetres and 7.25 millimetres. The aerosol-generating article may have a length, for example, between 10 millimetres and 60 millimetres, between 15 millimetres and 50 millimetres, or between 20 millimetres and 45 millimetres.

The aerosol-generating substrate may include a flavorant. Botanical materials provide a flavorant that can impart a flavor to the taste of the aerosol generated by the aerosol-generating article. A flavorant is any natural or artificial compound that affects the organoleptic quality of the aerosol. Non-limiting examples of flavorant sources include mints, such as peppermint and spearmint, coffee, tea, cinnamon, clove, cocoa, vanilla, eucalyptus, geranium, agave, and juniper, and combinations thereof.

The aerosol-generating substrate may include an essential oil. Essential oils may provide a flavorant that can impart a flavor to the flavor of the aerosol generated by the aerosol-generating article. Suitable essential oils include, but are not limited to, eugenol, peppermint oil, and spearmint oil. A preferred essential oil is eugenol. The essential oil may be present in the aerosol-generating substrate in an amount of at least about 0.1% by weight, or at least about 0.5% by weight, or at least about 1% by weight. The essential oil may be present in the aerosol-generating substrate in a range of about 0.1% by weight to about 10% by weight, or about 0.1% by weight to about 5% by weight, or about 0.5% by weight to about 2%.

The aerosol-generating substrate may include homogenized tobacco material. The homogenized tobacco material may include tobacco material, from about 1 percent to about 5 percent of a binder, and from about 5 percent to about 30 percent of an aerosol former, on a dry weight basis. The aerosol-generating substrate may include homogenized tobacco material. The homogenized tobacco material may include tobacco material, from about 1 percent to about 5 percent of a binder, and from about 10 percent to about 30 percent glycerin, on a dry weight basis.

Sheets of homogenized tobacco material for use in the aerosol-generating article of the present invention may be manufactured by methods known in the art, for example the methods described in international patent application WO-A-201 2/1 64009 A2. In a preferred embodiment, sheets of homogenized tobacco material for use in the aerosol-generating article are formed from a suspension comprising particulate tobacco, guar gum, cellulosic fibers and glycerin by a molding process.

The aerosol-generating substrate may include a gathered sheet of homogenized tobacco material, which is preferably crimped. As used herein, the term "crimped" denotes a sheet having a plurality of essentially parallel ridges or corrugations. Preferably, when the aerosol-generating article has been assembled, the essentially parallel ridges or corrugations extend along, or are parallel to, the longitudinal axis of the aerosol-generating article.

An aerosol generating system may comprise: an aerosol generating article comprising the aerosol generating substrate element, as described herein, attached to a filter element, and an aerosol generating device comprising a heating element configured to heat the aerosol generating substrate element.

The heating element may be integral with an aerosol generating device and a consumable aerosol generating article may be releasably received within the aerosol generating device.

The heating element may be a combustible heat source, a chemical heat source, an electrical heat source, a heat sink, or any combination thereof. Preferably, the heat source is an electrical heat source, in the form of a sheet that can be inserted into the aerosol-generating substrate. Alternatively, the heat source may be configured to surround the aerosol-generating substrate, and as such may be in the form of a hollow cylinder, or any other suitable shape.

Preferably the heating element is configured to heat the aerosol-generating substrate directly without transmitting heat to the aerosol-generating substrate through the first or second paper wrapper.

The aerosol-generating substrate may include an induction heating element or susceptor or a plurality of induction heating elements or susceptors. The induction heating elements or susceptors are heated in the presence of an alternating or fluctuating electromagnetic field. When heating is by induction heating, a fluctuating electromagnetic field is transmitted through the aerosol-generating article to the induction heating element or susceptor such that the susceptor or inductive heating element changes the fluctuating field to thermal energy thereby heating the aerosol-generating substrate.

The induction heating element or susceptor may be formed from any material that can be heated by induction to a temperature sufficient to generate an aerosol from the aerosol generating substrate. The induction heating element or susceptor may comprise a metal or carbon. A preferred inductive heating element or susceptor may comprise a ferromagnetic material, for example ferritic iron, or a ferromagnetic steel or stainless steel. The induction heating element or susceptor may comprise aluminum. The inductive heating element or susceptors may be formed from 400 series stainless steels, for example 410 grade, or 420 grade, or 430 grade stainless steel. Different materials will dissipate different amounts of energy when placed within electromagnetic fields having similar values of frequency and field strength. Preferably, the induction heating element or susceptors are heated to a temperature greater than 250 degrees Celsius. However, preferably the induction heating element or susceptors are heated to less than 350 degrees Celsius to avoid burning the material in contact with the susceptor.

The aerosol-generating substrate may comprise a metallic induction heating element. The metallic induction heating element may comprise a plurality of metallic induction heating elements. The metallic induction heating element may comprise a metallic induction heating ring element.

This first paper wrapper may exhibit a range of permeability including not being permeable. The permeability of the cigarette paper is determined using the international standard test method ISO 2965:2009 and the result is presented as cubic centimeters per minute per square centimeter and is referred to as “CORESTA units.” The permeability of the first paper wrapper described herein may be in a range of about 1 to about 10 CORESTA units, about 5 to about 20 CORESTA units, or about 1 to about 5 CORESTA units.

The first layer of paper wrapping can be formed from any cellulosic material such as paper, wood, cloth, natural as well as artificial fibers.

This second paper wrapper may exhibit a range of permeability including being non-permeable. The permeability of the cigarette paper is determined using the international standard test method ISO 2965:2009 and the result is presented as cubic centimeters per minute per square centimeter and is referred to as “CORESTA units.” The permeability of the second paper wrapper described herein may be in a range of about 1 to about 10 CORESTA units, about 5 to about 20 CORESTA units, or about 1 to about 5 CORESTA units.

The second layer of paper wrapping can be formed from any cellulosic material such as paper, wood, cloth, natural as well as artificial fibers.

The first or second paper layer may comprise a laminate of a paper layer and a metal layer. The first paper layer may comprise a laminate of a paper layer and a metal layer. The second paper layer may comprise a laminate of a paper layer and a metal layer. The first and second paper layers may comprise a laminate of a paper layer and a metal layer.

The metallic layer may be an aluminum layer. The first and second paper layers may comprise a laminate of a paper layer and an aluminum layer. The laminate of a paper layer and an aluminum layer may have a uniform thickness in a range of about 78 micrometers to about 160 micrometers, or about 78 micrometers to about 140 micrometers, or about 100 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers. The laminate of a paper layer and a metallic layer may not extend beyond the ends of the aerosol-generating substrate.

The RTD of the aerosol-generating article after insertion into the aerosol-generating device is preferably between about 80 mm WG and about 140 mm<W g ,>more preferably between about 100 mm WG and about 120 mm WG.

As used herein, the aspiration resistance is expressed in the pressure units of “mm WG” or “mm of water column” and is measured in accordance with ISO 6565:2002. The aspiration resistance (RTD) of the aerosol-generating substrate rod is preferably between about 50 mm WG and about 80 mm WG. Preferably, the RTD of the aerosol-generating substrate rod is between about 5 mm WG and about 8 mm WG per millimeter of rod length.

All scientific and technical terms used in this description have meanings that are commonly used in the art unless otherwise specified. The definitions provided in this description are to facilitate the understanding of certain terms frequently used in this description.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” encompass examples having plural referents, unless the content clearly dictates otherwise.

As used in this description and the appended claims, the term “or” is generally used in a sense that includes “and/or” unless the content clearly indicates otherwise.

As used herein, “has,” “having,” “includes,” “including,” “comprises,” “comprising,” or the like are used in their broad sense, and generally imply “including, but not limited to.” The expression “consisting essentially of,” “consists of,” and the like will be understood to be included in “comprising” and the like.

The words “preferred” and “preferably” refer to examples of the invention that may provide certain advantages under certain circumstances. However, other examples may also be preferred under the same or other circumstances. Furthermore, the recitation of one or more preferred examples does not imply that other examples are not useful and is not intended to exclude other examples from the scope of the description, including the claims.

Figure 1 is a cross-sectional schematic diagram of an aerosol-generating article.

Figure 2 is a cross-sectional schematic diagram of the first paper wrap and the second paper wrap before being wrapped around the aerosol-generating substrate.

Figure 3 is a cross-sectional schematic diagram of the aerosol generating substrate element along line 3-3 in Figure 1.

Figure 4 is a cross-sectional schematic diagram of the aerosol generating substrate element along line 4-4 in Figure 3.

Figure 5 is a cross-sectional schematic diagram of an aerosol generating system.

Figure 6 is a cross-sectional schematic diagram of a heating sheet inserted into the aerosol generating substrate element.

The aerosol-generating articles depicted in Figures 1-6 illustrate one or more examples of aerosol-generating articles, components of aerosol-generating articles, or aerosol-generating systems described above. The schematic drawings are not necessarily to scale and are presented for illustrative purposes and are not intended to be exhaustive. The drawings depict one or more aspects described in this disclosure. However, it will be understood that other aspects not depicted in the drawings fall within the scope of this disclosure.

The aerosol-generating article 10 of Figure 1 illustrates an aerosol-generating substrate element 12 that includes an aerosol-generating substrate 20 wrapped with the double paper wrapper 30. An intermediate section 24 separates a filter element 22 from the aerosol-generating substrate element 12. The aerosol-generating substrate element 12, the intermediate section 24, and a filter element 22 are aligned from a distal end 13 to a proximal end 11 in serial order and form a cylinder. A tipping paper or tip wrapper 40 circumscribes the aerosol-generating article 10 to attach the aerosol-generating substrate element 12 to the intermediate section 24, and a filter element 22.

The intermediate section 24 may comprise on or more than one hollow tube of cellulose acetate or a polylactic acid filter segment. The filter element 22 may define a nozzle segment and be formed of cellulose acetate material. The aerosol-generating substrate element 12, the intermediate section 24, and a filter element 22 may be individually wrapped with a layer of paper and then joined together with the paper nozzle or tip wrap 40. In particular, the aerosol-generating substrate element 12 is wrapped with the double paper wrap 30, as described herein.

The aerosol-generating article 10 has a mouth-side end or proximal end 11 and an upstream distal end 13 located at the opposite end of the article to the mouth-side end 11. The aerosol-generating article 10 shown in Figure 1 is particularly suitable for use with an electrically operated aerosol-generating device comprising a heater for heating the aerosol-generating substrate element 12.

Figure 2 is a cross-sectional schematic diagram of the first paper wrap 31 and the second paper wrap 32 or the double paper wrap 30, before being wrapped around the aerosol-generating substrate 20. Figure 3 is a cross-sectional schematic diagram of the aerosol-generating substrate element 12 along line 3-3 in Figure 1. Figure 4 is a cross-sectional schematic diagram of the aerosol-generating substrate element 12 along line 4-4 in Figure 3.

A first paper wrapper 31 comprises opposing edges that abut one another to circumscribe the aerosol-forming substrate 20 and form a first seam line 35. A second paper wrapper 32 comprises opposing edges that abut one another to circumscribe the first paper wrapper 31 and form a second seam line 34. The first seam line 35 is offset from the second seam line 34 and the first paper wrapper 31 and the second paper wrapper 32 do not extend beyond the aerosol-generating substrate 20 or beyond the ends 25, 26 of the aerosol-generating substrate 20.

The double paper wrapper 30 circumscribes the aerosol-generating substrate 20 to define the aerosol-generating substrate element 12 having a substantially cylindrical shape. The aerosol-generating substrate 20 defines a substantially cylindrical shape having a diameter 23 in a range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm. The aerosol-generating substrate element 12 defines a substantially cylindrical shape having a diameter 33 in a range of about 7.1 mm to about 7.3 mm, or about 7.15 mm to about 7.25 mm.

The double paper wrapper 30 has a thickness T in a range of about 60 micrometers to about 200 micrometers. The paper wrapper 30 may preferably have a thickness in a range of about 78 micrometers to about 160 micrometers, or about 78 micrometers to about 140 micrometers, or about 90 micrometers to about 140 micrometers, or about 100 micrometers to about 140 micrometers, or about 110 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers, or about 130 micrometers to about 140 micrometers.

The double paper wrapper 30 has a ratio of the thickness of the paper T to the diameter of the tobacco substrate 23 in a range of about 1:120 to about 1:40, or about 1:100 to about 1:50, or about 1:70 to about 1:50, or about 1:60 to about 1:50.

The double paper wrap 30 circumscribes the entire circumference of the aerosol generating substrate 20 without overlapping the first paper wrap 31 over itself and without overlapping the second paper wrap 32 over itself. The double paper wrap 30 defines less than three layers of paper at any point around the circumference of the aerosol generating substrate element 12.

Figure 5 is a cross-sectional schematic diagram of an aerosol generating system 201. Figure 6 is a cross-sectional schematic diagram of a heating sheet 230 inserted into the aerosol generating substrate element 12. The aerosol generating article 10 can be used with the aerosol generating device 200 as illustrated in Figure 5 and Figure 6.

The aerosol generating device 200 includes a housing 210 defining the receptacle 220, configured to receive the aerosol generating article 10. The aerosol generating device 200 also includes a heating foil element 230 configured to pierce the aerosol generating substrate element 12 of the aerosol generating article 10. The heating foil element 230 may comprise an electrically resistive heating component. In addition, the device 200 includes a power supply 240 and electronic control circuitry 250 that cooperate to control heating of the heating foil element 230.

The aerosol-generating article 10 illustrates an aerosol-generating substrate element 12, an intermediate section 24, and a filter element 22 aligned from a distal end 13 to a proximal end 11 in serial order and forms a cylinder. The distal end 13 of the aerosol-generating article 10. The aerosol-generating substrate 12 has a length of approximately 12 millimeters. The aerosol-generating substrate 12 has a cylindrical shape and an essentially circular cross section. The aerosol-generating substrate 12 may comprise a shirred sheet of homogenized tobacco material. The sheet of homogenized tobacco material may comprise approximately 10 weight percent on a dry weight basis of glycerin. The intermediate section 24 may be a hollow tube of cellulose acetate having a length of approximately 8 millimeters and a thickness of 1 millimeter. The mouthpiece segment or filter element 22 may comprise a tow plug of 8 denier per filament cellulose acetate and has a length of approximately 7 millimeters.

Figure 6 illustrates the heating foil element 230 disposed within the aerosol-generating substrate 12. The heating foil element 230 may heat the aerosol-generating substrate 12, 20 of the aerosol-generating article 10. Heating the aerosol-generating substrate 12 causes the aerosol-generating substrate 12 to generate an aerosol containing the nicotine that may be transferred out of the aerosol-generating article 10 at the proximal end 11.

The heating foil element 230 may have a width 233 of about 5 mm. The aerosol-generating substrate 20 defines a substantially cylindrical shape having a diameter 23 in a range of about 6.8 mm to about 7.1 mm. The aerosol-generating substrate element 12 defines a substantially cylindrical shape having a diameter 33 in a range of about 7.1 mm to about 7.3 mm. The heating foil element 230 may be less than about 1 mm from the double paper wrapper 30.

In some examples the heating mechanism may be induction where the heating element emits radiomagnetic radiation that is absorbed by one or more metallic induction heating elements when the aerosol generating article 10 is positioned in the receptacle 220 of the aerosol generating device 200.

Once the aerosol generating article 10 has been releasably inserted into the aerosol generating device 200 and the heating sheet element 230, the aerosol generating device 200 is actuated to heat the aerosol generating substrate 12 to a temperature of approximately 375 degrees Celsius. When a user draws on the mouth-side end 11 of the aerosol generating article 10, volatile compounds released from the aerosol generating substrate 12 are drawn downstream through the aerosol generating article 10 and condense to form an aerosol that is drawn through the mouthpiece 11 of the aerosol generating article 10 into the user's mouth.

The illustrative examples described above are not limiting. Other examples consistent with the illustrative examples described above will be apparent to those skilled in the art.

Claims (14)

1. An aerosol generating substrate element (12) comprising: a cylindrical aerosol generating substrate (20) comprising from about 10% to about 30% glycerin by weight; a first paper wrapper (31) comprises opposite edges abutting each other to circumscribe the aerosol-forming substrate and form a first seam line (35); a second paper wrapper (32) comprises opposite edges abutting each other to circumscribe the first paper wrapper and form a second seam line (34); and the first seam line is offset from the second seam line and the first paper wrap and the second paper wrap do not extend beyond the aerosol generating substrate. 2. The aerosol-generating substrate element according to claim 1, wherein the first stitching line is offset from the second stitching line by at least about 5%, or at least about 10%, or at least about 15% of a circumference of the aerosol-generating substrate. 3. The aerosol-generating substrate element according to any preceding claim, wherein the aerosol-generating substrate is circumscribed by less than three layers of paper at any point around a circumference of the aerosol-generating substrate that do not extend beyond the aerosol-generating substrate. 4. The aerosol-generating substrate element according to any preceding claim, wherein the first paper wrapper and the second paper wrapper have a combined thickness in a range of about 60 microns to about 200 microns, or 78 microns to about 160 microns, or 78 microns to about 140 microns, or about 100 microns to about 140 microns, or about 125 microns to about 140 microns. 5. The aerosol-generating substrate element according to any preceding claim, wherein the first paper wrapper and the second paper wrapper have a uniform combined thickness that does not differ at any point around a circumference of the aerosol-generating substrate element by more than about 30 microns, or more than about 20 microns, or more than about 10 microns, or more than about 5 microns. 6. The aerosol-generating substrate element according to any preceding claim, wherein the aerosol-generating substrate has a diameter in a range of about 6.8 mm to about 7.1 mm. 7. The aerosol-generating substrate element according to any preceding claim, wherein the at least first paper wrapper and the second paper wrapper have a ratio of combined paper thickness to tobacco substrate diameter in a range of about 1:120 to about 1:40, or about 1:100 to about 1:50. 8. The aerosol-generating substrate element according to any preceding claim, wherein the aerosol-generating substrate comprises homogenized tobacco material. 9. The aerosol-generating substrate element according to claim 8, wherein the homogenized tobacco material comprises tobacco material, from about 1 percent to about 5 percent of a binder, and from about 10 percent to about 30 percent glycerin, on a dry weight basis. 10. The aerosol-generating substrate element according to any preceding claim, wherein the aerosol-generating substrate comprises a metallic induction heating element. 11. The aerosol-generating substrate element according to any preceding claim, wherein the aerosol-generating substrate comprises a plurality of metallic induction heating elements. 12. An aerosol generating system (201) comprising: an aerosol-generating article (10) comprising the aerosol-generating substrate element according to any preceding claim attached to a filter element (22); and an aerosol generating device (200) comprising a heating element (230) configured to heat an aerosol generating substrate element. 13. The aerosol generating system according to claim 12, wherein the heating element is a resistive heating sheet element configured to be inserted into the aerosol generating substrate element. 14. The aerosol generating system according to claim 12, wherein the heating element is an inductive heating element configured to inductively heat metallic inductive heating elements incorporated within the aerosol generating substrate element.